Method for securing a yoke to a tube using magnetic pulse welding techniques

Abstract

A magnetic pulse welding operation is performed to secure first and second metallic components together, such as a yoke and a driveshaft tube in a vehicular driveshaft assembly. The yoke includes a first portion, such as a body portion, and a second portion, such as a pair of opposed yoke arms. The end of the driveshaft tube is disposed co-axially about the body portion of the yoke. An inductor axially is positioned co-axially about the overlapping portions of the end of the driveshaft tube and the body portion of the yoke. The inductor is energized to perform a magnetic pulse welding operation to secure the end of the driveshaft tube to the body portion of the yoke without generating a significant flow of air toward the inductor.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit of U.S. Provisional Application No. 60 / 362,215, filed Mar. 6, 2002, the disclosure of which is incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]This invention relates in general to the use of magnetic pulse welding techniques to secure two metallic components together, such as a yoke and a driveshaft tube in a vehicular driveshaft assembly. In particular, this invention relates to an improved method for performing such a magnetic pulse welding operation that protects the inductor from potential damage that can result from the performance of this operation.[0003]In most land vehicles in use today, a drive train system is provided for transmitting rotational power from an output shaft of an engine / transmission assembly to an input shaft of an axle assembly so as to rotatably drive one or more wheels of the vehicle. To accomplish this, a typical vehicular drive train assembly includes a hol...

AI Technical Summary

Benefits of technology

[0010]This invention relates to an improved method for performing a magnetic pulse welding operation to secure two metallic components together, such as a yoke and a driveshaft tube in a vehicular driveshaft assembly, that protects the inductor from potential damage that can result from the performance of this operation. The yoke includes a first portion, such as a body portion, and a second portion, such as a pair of opposed yoke arms. The end of the driveshaft tube is disposed co-axially about the body portion of the yoke. An inductor axially is positioned co-axially about the overlapping portions of the end of the driveshaft tube and the body portion of the yoke. The inductor is energized to perf

Problems solved by technology

As is well known, conventional welding techniques involve the application of heat to localized areas of two metallic members, which results in a coalescence of the two metallic members.

Such conventional welding techniques may or may not be performed with the application of pressure, and may or may not include the use of a filler metal.

Although conventional welding techniques have functioned satisfactorily in the past, there are some drawbacks to the use thereof in joining the first and second end fittings to the ends of the driveshaft tube.

This application of heat can cause undesirable distortions and weaknesses to be introduced into the metallic components.

Second, while conventional welding techniques are well suited for joining components that are formed from similar metallic materials, it has been found to be somewhat more difficult to adapt them for use in joining components formed from dissimilar metallic materials.

Third, conventional welding techniques are not easily adapted for joining components that have different gauge thicknesses.

In this instance, the insulation and other elements of the inductor can be contaminated and otherwise adversely affected in a short number of welding cycles.

For example, insulation provided on the inductor can degrade significantly fast if the air and other portions of the cumulative flow are captured inside a closed space, the volume of which decreases fast.

Obviously, this is unacceptable in a manufacturing process because breakdown of the inductor is possible.

The high velocity secondary flow created during the magnetic pulse welding operation impinges upon the shield, thus protecting the inductor therefrom premature.

However, the use of such a shield has been found to be relatively time-consuming and, therefore, relatively inefficient, particularly in the context of the high volume production process associated with the manufacture of vehicular driveshaft assemblies.

Images